Uphill Simulation
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Transcript of Uphill Simulation
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Bilal Masood
Supervisor Zhe Tan
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1. Simulate the uphill teeming process using two CFD softwares:
} ANSYS Fluent 13.0 } COMSOL Multyphysics 4.1
2. Study the effect of mould geometry and velocity of molten metal on the flow pattern inside the uphill teeming process.
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1. Geometry 2. Meshing 3. Set up 4. Solution 5. Results
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Velocity : 0.3 , 0.7 and 1.1 m/s Flaring angle : 0 , 6 , 12 and 18
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1. Creating 3D Geometry in ANSYS DesignModeler
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2. Meshing : Meshing the geometry in ANSYS Meshing aplication Creating named selections for the geometry boundaries
Flaring angle No. of nodes No. of elements
0 12543 55282 6 12419 54687
12 12091 53075 18 11917 52226
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3. Set up: CFD Simulation set up in ANSYS Fluent
General set up: Solver type : Pressure-Based Time : Steady Gravity (y-direction): -9.81 m/s2
Model: Energy Equation Viscous Model k
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3. Set up : Set Up the CFD Simulation in ANSYS Fluent
Materials: Fluid Molten Steel
Material property Value Unit Density 7010 Kg/m3 Viscosity 0.006 N s/m2 Heat capacity (Cp) 750 j/kg k Thermal conductivity (k) 41 W/m k
Boundary Conditions: velocity-inlet Velocity magnitude : 0.3, 0.7, 1.1 m/s Thermal : 1900 K Velocity-outlet Gauge pressure : 0 Pa Thermal : 1800 K Symmetry
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4. Solution: Calculation running
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5. Results Displaying results in ANSYS CFD-Post
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5. Results Displaying results in ANSYS CFD-Post Flaring angle = 0
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Flaring angle = 6
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Flaring angle = 12
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Flaring angle = 18
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Simulating uphill teaming using COMSOL 4.1
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3D 2D
Simulation type
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2D SIMULATION
Geometry
Physics
Material
Study
Results
Solid edge ST
Turbulent flow
Heat Transfer
Mesh
Stationary
Liquid Steel
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3D SIMULATION
Geometry
Physics
Material
Study
Results
Solid edge ST
Turbulent flow
Mesh
Stationary
Liquid Steel
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Material
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2D 3D
Turbulent flow
Turbulent flow
Heat Transfer
Physical model
Incompressible k
Initial Values P=0
U=0
Inlet
Velocities 0.3 0.7 1.1
Outlet P=0
Physical model
Initial Values
Inlet
Outlet
Incompressible k
P=0 U=0
Velocities 0.3 0.7 1.1
P=0
Initial Values
Temperature
Convective cooling
1800K
1900K
h=5
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3D 2D
Angle Variation
0 6
12 18
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2D 3D
Stationary Time Dependent Stationary
Solved Not Solved Solved Not
Solved
Time Dependent
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6 Degree 18 Degree
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Results 3D 6 Degree 18 Degree
12 Degree
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Conclusion
For the all angles and the velocities the best results obtained are from the 6 degree angle 0.7 velocity. Hence it will help to improve the mechanical properties of the casted parts.This velocity of fluid contains very less number of the eddies and fine temperature distribution in the mold .Hence angle 6 degree with the 0.7 m/s velocity is recommended.
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Comparison of the ANSYS and COMSOL
By looking at both results obtained from the two software ANSYS Fluent and COMSOL Multiphysics, it can be realized that the best design of the mold is with 6 degrees flaring with different velocities especially 0.7 m/s which give the best velocity distribution and less vortices
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THANKS